Method and apparatus for converting bulk filament into staples



5 Sheets-Sheet 1 March 23, 1948. R C, wlLKlE METHOD AND APPARATUS FORCONVERTING BULK FILAMENT INT0 STAPLES Filed March 1, 1943 March 23,1948. R. c. wlLKlE METHOD AND APPARATUS FOR CONVERTING BULK FILAMENTINTO STAPLES Filed March 1 1943 5 ASheets-Sheet 2 -l Il mom.

JYVIIII'III m/ fi Rom Cum@ R. C. VVILKIE March 23, 1948.

METHOD AND APPARATUS FOR CONVERTING BULK FILAMENT INTO STAPLES s-Sheet 3Filed March l, 1943 March 23, 1948. R. c. wlLKlE 2,438,469

METHOD AND APPARATUS FOR CONVERTING BULK FILAMENT INTO STAPLES FiledMarch 1, 1943 5 Sheets-Sheet 4 vom Q Q3 msm. Sm .f @uw l i am vh .0 .mmfmf om man www Mov msw F March 23, 1948. R. c, wlLKlE METHOD ANDAPPARATUS Fon coNvERTlNG BULK FILAMEN'T INT0 STAPLES Filed March l, 19455 Sheets-Sheet 5 @bm Qumlu @WW GWW en@ nm I aveza'o'af.-

Patented Mar. 23., 1948 OFFICE METHOD AND APPARATUS FOR CONVERT- INGBULK FILAMENT INTO STAPLES Robert C. Wilkie, Andover, Mass., assigner toPacific Mills, Lawrence, Mass., a corporation of MassachusettsApplication March 1, 1943, Serial No. 477,608 In Canada November 23,1941 30 Claims. (Cl. 19-150) This invention relates to a process andmachine for converting bulk filament, such as rayon, of continuouslengths into a sliver of drafted and separated staples ready to be drawnand spun into yarn either alone or after mixing with other bers suchI aswool. Its object is to produce an even, self-sustaining sliver withoutthe necessity for picking, carding, gillng, combing or the like.

In the drawings:

Fig. 1 is a plan view of the right-hand, inlet end of a machine made inaccordance with the preferred embodiment of my invention;

Fig. 2 is a side elevation view of the portion of the machine shown inFig. 1;

Fig. 3 is a plan view of the left-hand, delivery end of the machineshowing some parts in common with Fig. 1 to indicate how the two viewscombine to show the entire machine;

Fig. 4 is a side elevation view of the portion of the machine shown inFig. 3;

Fig. 5 is an enlarged plan view of the upper fracturing roll showing itseffect on the web of continuous filaments;

Fig. 6 is an enlarged vertical section of the debonding apparatus;

Fig. 7 is an enlarged side elevation view, partly in section on the line'l-l of Fig. 3, showing the collecting cylinder;

Fig. 8 is a diagrammatic vertical section showing the shearing action;

Fig. 9 is a diagrammatic side elevation view of the driving mechanism.

Fig. 10 is a side elevation view of a modification; and

Fig. 11 is a side elevation view of a further modification.

I will first describe my preferred process for converting continuousfilaments into a continuous sliver of non-conterminous separated anddrafted staples. By staples I mean the individual pieces into which thefilaments are severed in my process and machine.

The rst step is to collect the continuous filaments and spread them intoa at web. To accomplish this, they are drawn from spools i30 (Fig. 1)and led through apertures E38 in a guide frame M to feed rolls |44, H46and S48, about which they pass to emerge as a dat web 8.

The next step is to cut or fracture the web into oblique strips I6 (Fig.5) extending at an angle to the line of feed, preferably of about 10.This is accomplished by one, or more, blunt helical steel threads i4 onthe periphery of roll i0 which are pressed strongly against the websupported by the plain metal surface of roll I 2. The lengths of thestaples between the cuts or fractures may be varied by presenting theweb to the threads at dierent angles by moving the frame |40 sidewise,as will be fully described. Staples, thus produced, of varying lengthssimulate the variations in staple length in a wool, worsted or cottonsliver, as is greatly desired.

The forward feeding of the web and strips is assisted by rubberymaterial |60 between the threads i4 on roll I0. This material alsoprevents the web from being fed sidewise by the threads.

The next step is to separate the ends of staples which are stucktogether by portions of the filaments which were crushed and spread bythe blunt threads I4 and to break off those portions. This isaccomplished by rolls 24, 26 (Fig. 6), having iiutes 32 and 34respectively, in cooperation with rolls 20, 22 of slower peripheralspeed than that of the surfaces of the uted rolls and with roll 28 andapron 36 of faster surface speed. The iiutes are spaced apart so thatthey can move relatively to the web. They work and bend the filaments upand down and wipe the leading ends of those staples whose trailing endsare held by the nip of the slower moving rolls 20, 22 and they also wipethe trailing ends of those staples which are pulled between them by thefaster moving roll 2B and apron 36, so that any crushed portions adhering the ends together are removed.

Another step is to advance the staples lying on top of the web withrespect to those below, an operation which I call shearing This is acmcomplished by rolls 28, 44 and 46, which bear on the top staples andhave a greater peripheral speed than the surface of an apron 36, onwhich the bottom staples rest. Further shearing is ac-L complished inthe same way by the rolls 62, 6tand 66 and apron 60.

Another step is to draft the staples by the greater surface speed of therolls or aprons by which they are successively engaged.

By this shearing and drafting, adjacent staples are renderednon-conterminous and caused te overlap one another lengthwise bothvertically and laterally. All staples are merged into a prac ticallycontinuous and comparatively thin web 8a (Figs. 3 and 4) composed ofsuch non-conterminous staples.

The final step is to roll this web helically into a sliver 2 disposeddiagonally across the line of travel of the web and deliver itlengthwise into a receiving trumpet 408. To accomplish this, the web ofstaples is delivered by rolls 80, 82 to moving apron 86 and is picked upand wound on itself by a cylinder |00, which is diagonally inclined tothe feed of the web oppositely to the diagonal inclination of the stripsformed by the rolls I and I2 and rotates in such direction that itslower surface moves in the opposite direction to the travel of the web.Static electricity in the web is reduced by the metallic rollers 92 and94 electrically connected to the frame and by moistening the apron 86with water from a tank 2|0 applied by rolls 2I2 and 2|4.

The sliver, drawn through the trumpet |08 by rolls ||0 and I|2, is incondition for further processing, well known in the art, by which it maybe formed into thread.

'I'he sliver thus formed is very even in density so that it may be drawnand spun into yarn just as a sliver of wool or cotton is drawn and spun.Its staple bers are evenly distributed with none lying conterminously.If varying length staples have been made at the fracturing rolls, everysample of the sliver will show a good graduation of length. If awool-rayon mix yarn is desired, the sliver can be made with a graduationof staple length approximating that in the wool top with which it is tobe blended and the sliver and top, when blended, will produce awool-rayon top that can be drawn and spun into yarn in accordance withthe conventional worsted system. Similarly a cotton rayon mix can `beobtained.

The specic details of the machine by which I have achieved this resultcan be Varied considerably, but I have shown in the drawings apparatuswhich I have used effectively to convert many thousands of pounds ofrayon iilament into slivers of staple.

The packages |30 of continuous rayon filaments are supported on spindles|32 of creel 6,

from which the filaments are drawn by rolls |44,

|46 and |48 over a iiXed horizontal rod |34 and through holes I 38 inframe |40. The friction of the filaments 4 as they pass around thestationary rod |34 and against the beveled edges of the holes |38 checksslugs and prevents any twist in the filaments, as they unwind from thepackages, from being carried tothe fracturing rolls I0, I2.

The filaments are thus collected and spread into a web on the roll |46before delivery to the fracturing rolls.

The rolls |44, |46 and |48 are positively driven by mechanism to bedescribed at a peripheral speed which is slightly less than that atwhich rolls I0 and I2 are driven, so that the filaments between the twosets of rolls are under tension and are, therefore, straightened andparallelized as they reach the fracturing roll I0, I2. vThis tensionalso reduces crimp where crimped iilaments are employed. The nip ofrolls |46, |48

is slightly below the nip of rolls I0, I2, so that the filaments, whichenter the nip of the latter rolls, are pressed against the surface ofthe lower roll I2 and do not work themselves in between the side wallsof the threads I4 and the rubbery composition between the threads.

The helical threads I4 on the upper fracturing roll I0 are preferablynot sharpened but have fiat or slightly rounded 'edges which crush theweb of filaments supported by the lower roll I2. I have found that abreadthat the edge of $654 of an inch gives satisfactory results.

The threads on the roll l0 may be iiush with the surface of the rubberycomposition |60, which iills the spaces between the threads, but arepreferably slightly countersunk in the composition. The pressurebetweenthe rolls forces the composition back, exposing the edges of thethreads for fracturing the iilaments. The pressure of the compositionagainst the filaments enables the rolls I0 and I2 to feed the web andalso prevents any objectionable movement of the :filaments axially ofthe rolls. v

The roll I0 is cleaned of pieces of staple by the brush |84 rotatedcounter to the roll I0. The brush |84 is stripped by the card clothingon roll |86. The staple accumulates in the clothing where it iscompacted by brush |88 'and from which clothing it is periodicallyremoved.

The lower roll I2 is made of hardened tough steel alloy and presents asmooth, hard surface which supports the web 8 under the pressure of theupper roll I0.

'I'he roll l0 is mounted in spring-pressed bearings I 62 which apply aheavy pressure, of the order of several tons, to press the roll I0 downon the roll I2 to sever or fracture the filaments. The rolls I0 and I2are rotated by mechanism to be described and are geared together forequal surface speeds by intermeshing gears 322 and 324 (Fig. 9) at bothends of the rolls. To avoid undue wear of the surface of the lower rollby the edges of the threads, one of the rolls is slightly larger thanthe other and one of the gears in each pair may have one tooth more thanthe other gear.

The threads on the upper roll I0 cut or fracture the web of filaments 8into steeply oblique strips extending at an inclination determined bythe angle of the threads with relation to the axis of the cutting roll.For best results, this angle should be about 80 but it may, of course,be varied and should not be less than 60. I have obtained goodresultswith an angle as great as 88.

The acutely inclined cut leaves the ends of lat- Verally adjacentstaples successively behind one another. This causes the ends of therelatively advanced staples to be gripped and further advanced,relatively to those behind them, by the rolls and aprons to which theyare thereafter delivered along the line X of Fig. 5 and the length y ofthe cut staple is the distance a, perpendicular to the axis of the rollI0, between successive cuts I5 made by the threads. When the frame ismoved to the left the web of filaments is deliveredA at a slight angle,as shown at Y, Fig. 5, to this perpendicular. And when the frame is tothe right the lament web is delivered at the angle shown by Z. When theweb is delivered at the angle Y the staple lengths are longer and whenit is delivered at the angle Z they are shorter. By slowly reciprocatingthe frame the lengths of the staples may be varied from their longest totheir shortest and vice versa. This gives a graduated staple lengthwhich simulates the graduated lengths of woolen, worsted or cottonfibers and provides a sliver, with such graduations, which may thereforebe treated by the conventional worsted or cotton systems to form Thus. Ihave employed a roll I0' that is 51/2 inches in diameter, has fourstarts o! the fracturing helix I4 with a half-inch pitch and set at anangle of about 80. With the frame |40 idle and with the -web advancingin the direction X normal to theline of bite of the fracturing rolls, astaple length a approximating 41/2 inches is produced. The distance ofthe lower aperture |38 from the point of tandency of the filament withroll |44 is '7l/2 inches and employing 5 oscillations per minute of theframe |40 with an amplitude of l/2 inch each side of the center line, Ihave obtained a uniform graduation in staple length of fromapproximately 3 inches to 6 inches in all filament guided through saidlower aperture |38. These values, as well as others herein, are, ofcourse, merely for illustrative purposes and my invention is in no waylimited thereto. y

'I'he oblique strips of fractured staples are delivered to rolls 20, 22which are power driven to rotate at the same surface speed, which ispreferably the same as that of rolls and I2, or slightly greater. Theratch between rolls 20, 22 and rolls 24, 26 and the ratch between rolls24, 26 and the entering nip of roll 28 and apron 36 are both shorterthan the length of the shortest staple cut by roll I0. The rolls 20, 22nip the staples and restrain the trailing ends of those staples whoseleading ends are being worked and .wiped by the flutes 32, 34 on rolls24, 26. The rolls 20, 22, being small, may be placed very close to therolls 24, 26 and thereby restrain very short lengths of staples whoseleading ends are between rolls 24, 26.

The uted rolls 24 and 26 are geared together by gears 336 and 338 (Fig.9) to rotate at a surface speed greater than that of rolls 20 and 22.The fiutes of these rolls do not mesh together but merely enter to alimited extent the spaces between the flutes on the opposite roll andthis spacing is effected by employinga large enough diameter for thesegears. The spacing laterally between the adjacent sides of oppositeflutes is suicient so that the web and flutes can be moved relative toeach other and this spacing can be adjusted by using the same number offlutes on both rolls and driving gears on'both rolls having one toothmore than the number of flutes, so that the relative positions ofopposite flutes can be varied by selecting different meshing positionsof the driving gears.

The web of staples is then delivered to apron 36, running over rolls 30,38, 40 and 42 and returning around roll 43. Between successive rolls 30,38 and 40 and 42 are upper rolls 28,-44 and 46 against which the apron36 presses. Rolls 28, 44 and 46 are scratch iluted for better frictionalengagement with the staples pressed against them by the belt. The amountof this pressure can be adjusted by mounting roll 43 in verticallyadjustable bearings.

As the surface speeds both of apron 36 and rolls 28, 44, and 46 aregreater than that of rolls 20, 22, the web of staples is drafted. Thestaples in each strip i6 approach the roll 28 and apron 36 with theirleading ends on the fracture line l oblique to the entering nip betweenroll 26 and .apron 36, so that the staples in each strip are generallypresented successively rather than simultaneously to the rolls and belt.

'Ihe surface speed of rolls 28, 44 and 46 is greater than the surfacespeed of the apron 36 on which the web of staples lies, so that therolls advancev the upper staples of the web with respect to the stapleslying beneath them, as indicated diagrammatically ln Fig. 8. 'I'here isthus effected a separation and relative movement of the staples of theweb vertically with respect to each other, which I call a "shearingaction. As a result of this shearing action, the staples which werevertically aligned depthwise of the fracture line now flare out ofvertical alignment with some ends protruding more than others. Thereby,depthwise through the web, upper staples are advanced with relation tothose beneath them.

The staples are next presented to a further set of drafting rolls 50,52, the lower of which is scratch fluted, of the same peripheral speed,which is greater than that of rolls 28, 44 and 46. The rolls 58, 52positively nip the sta). es and draw them out from between the apron 36and the upper rolls 28, 44 and 46 which press against the staples withless firmness than the nip of rolls 50, 52.

I have found that the extended surface contact between the apron 36 andthe upper rolls 28, 44 and 46, as the result of the supporting positionsof the lower rolls 30, 38, 46 and 42, has several advantages. It enablesthe machine to obtain the desired shearing action with as little as 25%difference ln speeds between the apron and the upper rolls. The need fora predetermined ratch between rolls 20, 22 and the entering line ofengagement between roll 28 and apron 36, where the first draftingoccurs, is obviated because of the extended nip between the roll 28 andthe apron. Such elimination of specic :catches relative to staplelengths assists in properly drafting staples of varying lengths, such asare obtained either by a traverse reciprocation of the guide frame I 40or by substituting a fracturing roll with adiiferent inclination andspacing of the fracturing thread convolutions. Finally, the trailingends of those staples whose leading ends are in the nip of draftingrolls 50, 52 cannot cause curling of the staples which have not yetreached rolls 50, 52 and which are frictionally engaged by suchadvancing trailing ends because the staples so frictionally engaged arekept at between upper rolls and the supporting belt.

I prefer to repeat the shearing action. The web of staples passes fromthe nip of rolls 50, 52 to the apron 60, which passes over rolls 68, l0,'l2 and 14 and under adjustably mounted tension roll 16. The rolls 62,64 and 66, which are scratch uted, bear down on the staple web betweenthe rolls 68, 10, 'l2 and '14 and are run at a peripheral speed fasterthan the surface speed of the apron, whereby a further shearing actionis effected. The ratch between rolls 50, 52 and the entering line ofengagement between roll 62 and apron 68 may be considerably less thanthe staple length because, although rolls 50, 52 positively nip thestaples, the rolls 62, 64 and 66 press less firmly against them and willslip over staples held back by rolls 5|), 52.

A final pair of positive nip draft rolls and 82 rotates fasterperlpherally th'anrolls 62, 64 and 66 to effect a further drafting. Theroll 80 is stripped of loose staples by the stripper 202 provided Withfelt.

After the staple web has thus been sheared and drafted it is deliveredto apron 86, which runs around roll 82 and between it and roll 80 (Fig.3) and returns around roll 9D. The staple web delivered to the apron 86is made up of non-conterminous staples having leading and trailing endsdisposed haphazard throughout the web, and the web is thin compared withthe web of filament 8 which was delivered to the fracturing rolls.

In order to avoid the troubles occasioned by the presence of staticelectricity in the staple web, I provide means for minimizing it. Rolls92 and 94, having metallic surfaces electrically connected to the frameof the machine, are eective to conduct away static electricity. Bothrolls idle ron the web carried by apron-86. Roll 92 is of small diameterand is placed close to roll 80 so as to strip it of any adheringstaples. Similarly, roll 94 strips roll 92 and carries the strippedpieces to the web.

I preferably also humidify the room in which my machine is operated sothat the air has a relative humidity of about 60 to 65%.

For many types of rayon, such as viscose, the use of rolls 92, 84 wheretheatmosphere around the machine is humidiiied eliminates entirely anystatic, so that I can employ bulk rayon filament which has not beenprovided with the usual anti-static oil finish which, I have found, isapt to cause the staple to adhere together during treatment.

For other types of rayon, such as cellulose acetate, which present amore severe static problem, I also apply a limited amount of moisture tothe apron 86. The bottom of the apron, as it is moved rearward, picks upwater taken from a tank 2|0 by rolls 2|2 and 2|4. The roll 2|2 is feltcovered and the roll 2|4 is scratch uted. The roll 2|4 is power rotatedin the same direction as that of the surface of the apron which itcontacts and at a slower adjustable surface speed, so that the apronwipes the roll 2|4 and takes moisture from it. The quantity of moisturedeposited is determined in part by the depth and spacing of the scratchflutes on the roll 2I4 and may be varied by changing the relative speedsof roll 2|4 and the apron.

The final step is to wind the staple web into a helical sliver. 'I`hecylinder |00 has ribs |02 protruding from and winding spirally aroundits periphery and is rotated to advance its portion nearest the apron inthe opposite direction from the advance of the apron and at a speed atleast as great as that of the apron. The ribs b arely touch the apron.As the cylinder rotates it winds up the thin web of staple fibers into ahelical roll of sliver 2 which is drawn off through rotating trumpet |08by the rolls |I0, ||2. The axis of cylinder extends obliquely to thedirection of advance of the web and its inclination is opposite to theinclination of the lines of fracture |5. Although the,cut lines havebeen obliterated by the shearing action and the drafting, yet the web onapron 86 is extremely thin, any gaps in which extend in directions thathave the same general inclination as that of the lines of fracture. TheObliquity of the cylinder |00 is effective, not only to roll up thestaple fibers and enable them to be drawn oi the apron in helical form,but it also abruptly opposes any approaching gaps so that the staplesare collected in a sliver that has no thin places. The inclination ofthe ribs |02 should be in the direction shown so that their apparenttravel when the cylinder rotates is in the direction of advance of thesliver 2.

The cylinder |00 may be kept free of stray fibers by the use of an airjet 220 (Fig. 7) over it and having apertures 222` through which streamsof air are directed downwardly against the cylinder.

A stationary guide shield 226 having an e larged lip 228 guides thesliver as it is delivered to the rotating trumpet |08. 'I'he trumpet maybe provided with a sliver-receiving throat 240, triangular in crosssection, so that its rotation in the direction indicated imparts asimilar rotation to the sliver and aids in winding it up into helicalform. Rolls H0, I|2 are power'driven to draw the sliver from cylinder|00 and through the trumpet and deliver the sliver to a crimping box 223having the conventional weighted crimping blade 225 which operates in aknown manner toc 'legliver the sliver in crimped form, as shown a Themachine is preferably equipped with a stop motion finger which lightlyrests on the sliver between the stationary and rotating trumpets andstops the machine automatically if the sliver should break.

After the sliver hasv been formed and conducted away from the apron 86it may be provided with an anti-static oil finish of conventional sortfor inhibiting the generation of static in subsequent processingoperations.

Any suitable type of drive, of which the one shown in Fig. 9 is typical,may be employed to obtain the proper relative speeds of rolls andaprons.

The shafts for the several rolls are indicated in Fig. 9-'by the primesof the numbers used to designate the rolls in Fig. 2 and in Fig. 9 noattempt has, of course, been made to show the relative sizes of theelements with accuracy. 300 is the main power shaft rotatedcounterclockwise as by the motor diagrammatically shown at 302. Asprocket 304 fixed to shaft 300 carries a chain 306 which rotates asprocket 308 fixed to the shaft i2 to rotate the fracturing roll |2counterclockwise at a predetermined speed. A sprocket 3|0, also fixedtoy shaft I2', is connected by chain 3|2 to sprocket 3|4 on shaft |46'to rotate roll |46 counterclockwise at a surface speed which is the sameas or, for tension of the sliver, slightly less than the surface speedof roll l2. Gear 3|6 on shaft |46 meshes both with gear 3|8 on shaft |44and with gear 320 on shaft |48' to drive the rolls |44 and |48 at thesame surface speed as that of roll I 46.

The lower fracturing roll I2 drives the upper roll |0 by gear 322 fixedto shaft l2 meshing with gear 324 xed to shaft I0.

Roll 20 is driven from shaft I0' at the same surface speed as roll I0 orslightly faster by chain 326 running over sprocket 328 fixed to shaft I0and sprocket 330 on shaft 20. Lower roll 22 is driven by gear 332 fixedto shaft 22 and meshing with gear 334 fixed to shaft 20. The debondingrolls 24 and 26 are geared together by gears 336 on shaft 24 and 338 onshaft 26'. To drive both rolls at a surface speed faster than that ofrolls 20, 22, chain 340, extending around sprocket 342, is driven by asprocket 344 fixed to power shaft 300.

Rolls 28, 44 and 46 are driven at surface speeds greater than that ofrolls 24, 26 by chain 346 extending around sprocket 348 on shaft 24 andaround smaller sprocket 350 on shaft 28. Roll 44 is driven from roll 28at the same surface speed by chain 352 passing around sprockets 354 and356 on shafts 28 and 44.respectively. Roll 46 is driven from roll 44 atthe same surface speed by chain 358 passing around sprockets 360 and 362fixed to shafts 44' and 46' respectively.

Apron 36 is advanced at a surface speed less than that of rolls 28, 44and 46 but greater than that of rolls 24, 26 by suitably power drivingthe two end apron supporting rolls 30 and 42. Chain 366 passes aroundsprockets 388 and 318 fixed to shafts 30 and 42 respectively and aroundsprocket 368 fixed to jack shaft 310 which is f 9 driven from-shaft 300by chain 312 passing around sprockets 314 and 316, fixed to shafts 310and 300 respectively.

Rolls 50, 52 are geared together by gear 400 on shaft 50 and gear 402 onshaft 52. The lower of these rolls is driven at the relative speed abovedescribed by chain 404 passing aroundv sprocket 406 on shaft 52 andsprocket 408 on shaft d2.

The drives for the next set of rolls and belts may operate on the sameprinciple as that of the drives just described and therefore theirdetailed description is believed unnecessary. Rolls 62, 64 and 66 areconnected by chains and sprockets and the power is derived from shaft50' through chain 4 |'0 extending around sprocket 4 I2 on shaft 50 andsprocket 4|4 on shaft 62.

The shafts of the end rolls 68 and 14 supporting belt 60 carry sprocketsdriven by a chain 4|6 extending around sprocket 420 on shaft 422 whichis driven from shaft 310 by chain 424 passing around sprocket 426 onshaft 422 and around sprocket 428 on shaft 310.

Rolls 00, 82 are geared together by gear 430 on shaft 80' and gear 432on shaft 82'. Conveniently, the shaft 80' may be driven from shaft 66'employing sprocket 434 on the latter driving chain 1336 extending aroundsprocket 438 fixed to the former.

Cylinder is rotated by belt 462 passing around pulley 460 on thecylinder and pulley 464 on shaft 466 rotated from shaft 422 by bevelgears 468. Trumpetl may conveniently be driven by ring gear 5|0 mountedon the trumpet and meshing with gear 5| 2 on the shaft of cylinder |00.Rolls H0 and i2 are geared together by gears 5|4 and 5|@ and one ofthese rolls is connected to a going part of the machine, as indicateddiagrammatically by bevel gear 5|0 on the shaft of the lower rollmeshing with bevel gear 520 xed on the shaft of cylinder |00.

My invention is not limited to the specific embodiment above describedexcept as the appended claims require. As examples of modications whichI have found useful in practice, I may substitute for the aprons 36 and60, shown in Fig. 1, lower sets of rolls which, with the upper rolls,are so arranged as to effect the drafting and depthwlse shear of thestaples. Thus, Fig. 10, the iiuted rolls 24 and 26 may be followed byupper and lower rolls 236 and 232 which positively nip the staples androtate faster peripherally than the rolls 20, 22 to effect drafting andthe removal of mashed fragments of laments as the staples are advancedthrough the rolls 24, 26. An apron 234 is interposed between the rolls230 and 232 to avoid damage to the staples. The web 8 is delivered bythese rolls to a set of rolls numbered consecutively from 240 to 25|.The

-rolls 240, 24| are carrier rolls to support the web extending fromrolls 230, 232 to rolls 242, 243. Rolls 242, 243 are spaced from rolls230, 232 by a ratch approximating the staple length, or the maximumstaple length if there is a variation. Roll 243 rotates faster than roll232, and roll 242 rotates faster than roll 243. The speed differencebetween rolls 242 and 243 is preferably as much as 50%, although curlingof the staples by excess speed of the top roll should, of course, beavoided.

Rolls 242, 243 are spaced a very slight distance from each other, forexample, .002 inch for a web of about le inch average thickness, toadvance the staples frictionally and slip draft them. At least one ofthe' rolls 242, 243 is preferably covered with 10 l rubber or otherresilient material to -avoid damage to the staples and, because of thisresiliency, the spacing of .002 inch may be varied considerably withgood results. n

The intermediate carrier rolls 240 and 24| are spaced from each .other amore substantial amount, which may be greater than the web thickness atthis point. They are geared together by gears 256 and 258 to rotate at,the same peripheral speed, which is preferably between the speed ofroll 243 and that of roll 232. Because of the comparatively wideseparation of the carriers 240 and 24| from each other, they need not berubber covered but can be -of metal and preferably are scratch uted.Their surfaces should closely approach Without touching the rolls onboth sides of them, so that they strip those rolls of adhered staples.The scratch fiutings of the carrier aid their effectiveness for thispurpose.

A further lengthwise draft and depthwlse shear is effected by the rolls246, 241 with intervening rolls 244, 245 acting as carriers. The finalpair of carriers 248, 240 conveys the staple to the apron 86, from whichit is collected in sliver form.

As a still further modification, the apparatus in Fig. 11 may beemployed, having a plurality of upper rolls cooperating with a singlelower roll. The lower roll 243a corresponds, for example, with the roll243 in the embodiment of Fig. 10. In place of the upper roll 242 of Fig.10, I employ two small rolls 242a and 242b, both preferably made ofsteel, scratch uted and rotating at the same speed, which is preferablyconsiderably faster than the speed of the roll 243a from which they areslightly spaced, all as explained with reference to Fig. 10. The carrierrolls 240, 24| are shown on the right and 244, 245 are shown on theleft. I have found that the use of a plurality of small rollscooperating with a single larger roll gives a better surface contactwith the web and effects a better depthwise shear than ka pair ofopposite rolls.

My machine may be used on types of extruded filaments other than rayon.I have found that with some types of filament a depthwlse shear may beobtained through the use of upper rolls which are not power driven butrotate idly by surface contact with the web. Friction causes the upperrolls to drag behind the lower belt or rolls so that the upper surfaceof the web moves slower than its bottom surface.

The utility of my invention is not limited to its use on rayon or evenon other extruded filaments. Thus, where a continuous sliver of longfibers of any sort, whether animal, vegetable or artificial, isprocessed in my machine the individual lengths of the fibers may beshortened and a sliver of drafted staples made from it just as hereindescribed with relation to the conversion of continuous filaments.

In the specification and claims, where I refer to staples as beingfractured I mean that they are either fully severed or partly severedbecause they may be cut completely through by the threads or they may becrushed, without complete severance, and later broken apart.

This application is a continuation in part of my prior applicationSerial No. 343,819, led July 3, 1940, now abandoned, for Conversion ofbull: filament into staple form.

I claim:

1. Apparatus for producing a sliver of drafted staples from a web offilaments, which includes means for fracturing theweb along linesrunning l 1 across the web dividing the web into strips, each stripbeing composed of staples having fractured leading ends aligned witheach other along the forward fracture line of the strip, a plurality ofsets of staple-separating elements engaging the web along predeterminedlines across its opposite surfaces and through which the staples pass,at

least one of the elements of at least one of the sets advancing fasterthan an opposite element in the same set to urge one layer of thestaples to i the staples along a predetermined line, the fracturingmechanism and the staple-separating mechanism being so disposed relativeto each other that said lines of fracture and of element engagement forma predetermined angle relative to each other such that the alignedleading ends p of staples in a given laver are engaged and advancedsuccessively rather than simultaneously by opposed moving elements andsaid collecting cylinder being so disposed with relation to the saidfracturing means that the said line of collection has an inclinationdiagonally opposite to the lines of fracture whereby the drafted staplesare collected into a self-sustaining sliver.

2. Apparatus for producing a sliver of drafted staples from a web offilaments. which comprises a pair of filament fracturing rolls, means todrive said rolls. one of said rolls having a hard unyielding surface andthev other of said rolls having on its surface a blunt hard-surfacedhelical thread. the anale of inclination of the helix to the axis of theroll being between 60 and 88 to fracture the web into oblique stripsinclined to the direction of travel of the web from 2 to 30. each stripbeing composed of staples having their leading ends ou an oblique lineextending across the web. a plurality of opposed web-engaging elementsso mounted that the line of their entween 60 and 88 with said obliqueline, means to drive said web-engaging elements at surface i speedsgreater than the surface speed of the fracturing rolls, said elementsgripping and pulling the staples of said strip in succession as theforgagement with the web makes an angle of beward ends of said staplessuccessively enter the l line of engagement of said elements to advancea with relation to the staples adjacent to the other surface of saidweb. an apron adapted to receive the cut and drafted staples, means todrive said apron at a speed at least as great as the peripheral speed ofa web-engagingr element immediately preceding it. and a cylinder inproximity to the apron having its axis oblique to the direction oftravel of said staples at an inclination which l is in the samedirection as the inclination of said helix and diagonally opposite tothe inclination of said oblique strips. means to drive said cylinder ata peripheral speed at least as great as the speed of said apron with thesurface of said cylinder in proximity to the apron advancing in thedirection opposite to the direction of travel of said apron, saidcylinder being `adapted to contact with said staples on said apron andto form iiid staples into a helical roll of sliver and to guide saidsliver roll to advance in the direction of its axis.

3. Apparatus for producing a sliver oi drafted staples of differentlengths from a web of filaments, which comprises a pair of filamentfracturing rolls, means to drive said rolls, one of said rolls having ahard unyielding surface and the other of said rolls having on itssurface a blunt hard-surfaced helical thread, the angle of inclinationof the helix to the axis of the roll being between 60 and 88, means forguiding the web to said fracturing rolls at different inclinationsrelative to said inclination of the helix to fracture the web intooblique strips of staples of different lengths, each strip beingcomposed of staples having their leading ends on an obliquelineextending across the web, a plurality of opposed web-engagingelements so mounted that the line of their engagement with the web makesan angle of between 60 and 88 with said oblique line, means to-drivesaid web-engaging elements at surface speeds greater than the surfacespeed of the fracturing rolls, said elements gripping and pulling thestaples of said strip in succession as the forward ends of said staplessuccessively enter the line of engagement of said elements to advance astaple earlier gripped with relation to a staple later gripped, saiddriving means being also adapted to drive one element at a greatersurface speed than that of an opposite element to advance the staplesadjacent to one surface of said web with relation to the staplesadjacent to the other surface of said web, an apron adapted to receivethe' fractured and drafted staples, means to drive said apron at a speedat least as great as the peripheral speed of c. web-engaging elementimmediately preceding it, and a cylinder in proximity to the apronhaving its axis oblique to the direction of travel of said staples at aninclination which is in the same direction as the inclination of saidhelix and diagonally opposite to the inclination of said oblique strips,means to drive said cylinder at a peripheral speed at least as great asthe speed of said apron with the surface of said cylinder in proximityto the apron advancing in the direction opposite to the direction oftravel of said apron, said cylinder being adapted to contact with saidstaples on said apron and to form said staples into a helical roll ofsliver and to guide said sliver roll to advance in the direction of itsaxis.

4. The method of converting aweb of filaments into a sliver of fracturedand drafted staples which includes fracturing said web into stripsdisposed obliquely at an inclination of less than 30 to the longitudinalaxis of the web to produce fractured staples having leading ends in eachstrip substantially aligned at such an inclination to the longitudinalaxis of the web, drafting the web to effect a longitudinal separation ofsaid aligned fractured'ends in each strip by advancing said aligned endsin succession so that said fractured ends are no longer aligned at suchinclination, and rolling up the fractured and drafted staples into ahelical roll of sliver having its axis oblique to said longitudinal axisof the web at an inclination which is in the opposite direction to theinclination of said fracture.

5. Apparatus for producing staples from a web of filaments whichincludes in combination means for fracturing the web of filaments intostaples, and means for removing from adjacent fractured ends of thestaples mashed fragments of filament bcnding them together comprisingthree sucat a peripheral speed greater than that of the first set sothat the leading ends of staples grasped by the first set of rolls arewiped by said fiutings to remove fragments therefrom, and means forrotating the third set of rolls at a 4peripheral speed greater than thatof the second set so that the trailing ends of staples advanced by thethird set of rolls are caused to pursue said serpentine path to removefurther fragments therefrom.

6. Apparatus for producing staples from a web of filaments whichincludes in combination means for fracturing the web of filaments intostaples, and means for debonding adjacent fractured ends of the staplescomprising three successive sets of rolls throughwhich the staples pass,the first and last sets of which rolls positively grasp and advance thestaples and the intermediate set ofwhich rolls presents opposed flutingswhich intermesh with each other but are so spaced apart as to present anopen serpentine path through which the staples are advanced by saidfirst and last sets of rolls so that fragments of mashed filamentbonding together the fractured ends of staples are removed.

7. Apparatus for producing a sliver of staples from a web of filamentswhich includes means for fracturing the web into staples, means fordrafting and shearing the said staples, and means for rolling thestaples into a sliver, comprising' a traveling conveyor for supportingand advancing the staple web, a longitudinally ribbed cylinder disposedat an inclination to the path of advance of the conveyor and inproximity thereto, and means for rotating the cylinder in a directionopposite to the advance of the conveyor to roll the web of staples intoa sliver.

8. Apparatus as defined in claim 7 which also includes a membercontacting the staples adapted to conduct away static electricitytherefrom and means for applying moisture to the staples and to theapron in a predetermined controlled amount sufiicient to remove furtherstatic electricity from the staples but insuflicient to cause thestaples to adhere to said conveyor.

9. Apparatus for producing a sliver of staples from a web of filamentswhich includes means for fracturing the web along lines inclinedobliquely thereof to fracture the filamentl into staples, means fordrafting the staples, an apron adapted to receive the fractured anddrafted staples, a cylinder in proximity to the apron having its axisoblique to the direction of travel of said staples at an inclinationwhich is in the opposite direction to the inclination of said fractures,means to drive said cylinder at a peripheral speed at least as great asthe speed of said apron with the cylinder rotated oppositely to thedirection of travel of said apron, said cylinder being adapted tocontact with said staples on said apron and to form said staples into ahelical roll of sliver, and means for withdrawing said said sliver rollin the direction of its axis.

10. In the use of an apparatus for producing a web of staples from a webof filaments the process which includes the steps of fracturing thefilaments of the web into staples, separating the staples in said webdepthwise by advancing the web in the direction of their length Whilefrictionally engaging the upper and lower faces of said web andpositively driving one of said faces at a lower speed than the other ofsaid faces.

11. In the use Vof an apparatus for producing a web of staples from aWeb'of filaments the process which includes the steps of fracturing theweb of laments into staples and separating the staples in said webdepthwise by advancing the web in the direction of their length whilefrictionally engaging the upper and lower faces of said web and drivingone of said faces at a speed at least 25% faster than the other of saidfaces.

12. In a method of converting a web of filaments into a sliver ofdrafted staples the steps of fracturing said web into strips disposedobliquely at an angle of less than 30 to the longitudinal axis of theweb to produce fractured staples. separating the staples in differenthorizontal planes in said web depthwise by-advancing the web in thedirection of their length while frictionally engaging the upper andlower faces of said web and positively driving one of said faces at alower speed than the other of said faces and thereafter drafting thestaples in said web to effect a longitudinal separation of said staples.

13. `The method of converting a web of filaments into a sliver ofdrafted staples which includes fracturing said web into strips disposedobliquely at an angle of less than 30 to the longitudinal axis of theweb to produce fractured staples, separating the staples in differenthorizontal planes in said web depthwise by advancing the web in thedirection of their length while frictionally engaging the upper andlower faces of said web and positively driving one of said faces at alower speed than the other of said faces, pressing together said upperand lower faces with a pressure light enough to permit the staples inplanes between said faces to be drafted longitudinally, drafting saidstaples to effect a longitudinal separation of said staples and formingsaid staples into a sliver.

14. The method of converting a web of filaments into a sliver of draftedstaples of different lengths in a continuous movement, which methodconsists in feeding said web to fracturing means, fracturing said webalong steeply oblique lines, varying the angle in the plane of said webat which said web is fed to said fracturing means to produce obliquelyextending strips of staples of varying lengths, drafting said staples insaid strips to produce a thin web of drafted staples of a variety oflengths and forming said thin web into a sliver.

15. In a method of converting a web of filaments into a web of draftedstaples of different lengths, the steps which consist in feeding saidweb to fracturing means, fracturing said web along steeply oblique linesand varying the angle in the plans of said web at which said web is fedto said fracturing means to produce obliquely extending strips ofstaples of different lengths.

16. The method of converting a web of filaments into a sliver of draftedstaples of different lengths in a continuous movement, which methodconsists in feeding said web to fracturing means, fracturing said webalong steeply oblique lines, varying the angle in the plane of said webat which said web is fed to said fracturing means to produce obliquelyextending strips of staples of different lengths, drafting said staplesin said strips to ,f from a web of filaments having a main drivingshaft, means driven from said shaft for fracturing the web of filamentsinto staples, mechanism for advancing the web of fractured staples inthe direction of their length to separate them depthwise, said mechanismincluding an upper means having a movable surface frictionally engagingthe upper face of the fractured webvand a lower means having a movablesurface frictionally en- 1 gaging the lower face of the fractured web,and driving means driven from said shaft for driving each of said meansand including devices to drive one of said means at a surface speedslower 'than the surface speed of the other.

18. Apparatus for producing a web of staples from a web of filamentshaving a main driving shaft, means driven from said shaft for fracturingthe web of filaments into staples, mechanism for advancing the web offractured staples in the direction of their length to separate themdepthi wise, said mechanism including an upper means having a movablesurface frictionally engaging the upper face of the fractured web and alower means having a movable surface frictionally engaging the lowerface of the fractured web and driving means driven from said shaft fordriving each of said means and including devices to drive one of saidmeans at a surface speed at least 25% faster than the surface speed ofthe other.

19. Apparatus for producing a sliver from a web of filaments whichincludes in combination a pair of fracturing rolls comprising a smoothhard-surfaced roll and a roll having thereon blunt threads adapted tofracture the filaments supported on the smooth roll by pressurethereagainst, said threads being inclined at a steeply oblique angle tothe axis of the roll, means for varying the angle in the plane of saidweb at which said web is fed to said fracturing rolls to vary thelengths of the staples fractured by said threads, means for debondingsaid fractured staples, means following said debonding means to separatesaid staples in horizontal planes,

means to draft said staples and means to roll the drafted staples into aroll of sliver.

20. Apparatus for producing staples from a web of filaments whichincludes in combination i a pair of fracturing rolls comprising a smoothhard-surfaced roll and a roll having thereon blunt l threads adapted tofracture the filaments supported on the smooth roll by pressurethereagainst, said threads being inclined at a steeply oblique angle tothe axis of the roll, and means for varying the angle in the plane ofsaid web at which said web is fed to said fracturing rolls to vary thelengths of the staples fractured by said threads.

21. The method oi' converting filaments of textile fibers into a sliverof cut lengths which comprises forming a plurality of laments into afiat web, fracturing said web into steeply oblique strips of fracturedfibers, the ends of laterally adjacent fibers in a strip lying in anacute oblique line `diagonal to said web, drafting the bers to form aweb of cut drafted fibers, rolling 170 said web into a sliver having itsaxis diagonally disposed to the direction of the feed of the web andoppositely disposed to the diagonal `line on which said strips have beenfractured and advancing said sliver axially over said web.

22. Apparatus, for producing a sliver of cut lengths from a web of berfilaments which comprises means for fracturing the fibers of said web,means for drafting said fractured fibers, and means for rolling thefractured'drafted fibers into a sliver comprising a traveling conveyorfor supporting and advancing the web of fractured fibers, a ribbedcylinder disposed diagonally to the direction of advance of the conveyorand in proximity thereto and means for rotating the cylinder in adirection opposite to the advance of the conveyor to roll the web offractured drafted fibers into a sliver.

23. Apparatus for producing cut lengths from a web of fiber lamentswhich comprises in combination rollers for fracturing the web offilaments, one of said rollers having helical threads of one of saidrollers from contacting the utes of the other roller, means to drivesaid fiuted rollers at an equal surfacev speed greater than the surfacespeed of said fracturing rollers, web feeding means to which the web isdelivered from said fluted rollers and means to drive said web feedingmeans at a surface speed greater than the surface speed of said fiutedrollers, whereby the fractured laments are separated from one anotherand are formed into separate lengths of fibers.

24. The method for producing cut lengths from a web of fiber filamentswhich comprises fracturing and crushing the web of filaments on diagonallines, bending the web of fractured filaments repeatedly up and downwhile advancing said web at a speed greater than its speed during saidfracturing, thereafter advancing said web at a speed greater than itsspeed when bending the web, whereby the fractured filaments areseparated and formed into separate lengths of fibers.

25. Apparatus for producing separate cut lengths from a web of berfilaments which comprises in combination fracturing rollers forfracturing said filaments, one of said rollers having helical threadshaving cutting edges, a pair of luted rollers, each roller having fluteson its surface which project into the interflute spaces of the otherroller, said flutes being adapted to engage the opposite surfaces of thefractured web and to cause said webto undulate, means to maintain saidfluted rollers apart a sufficient distance to prevent the flutes of oneof said rollers from contacting theflutes of the other roller, means todrive said fluted rollers at an equal surface speed greater than thesurface speed of said fracturing rollers, web feeding means to which theweb is delivered from said fluted rollers and means to drive said webfeeding means at a surface speed greater than the surface speed of saidf-luted rollers, whereby the fractured filaments are separated from oneanother and are formed into separate lengths of fibers.

26. The method for producing separate cut lengths from a web of fiberfilaments in a continuous movement which comprises feeding the web oflaments to fracturng means, fracturing said moving web, bending said webrepeatedly transversely to its plane while advancing said web at a speedgreater than the speed of its movement during said fracturing andthereafter advancing said web at a speed greater than the speed of itsmovement during said bending, whereby the fractured filaments areseparated from one another and are formed into separate cut lengths.

lengths from a web of ber filaments in a continuous movement comprisingmeans to press helical threads having cutting edges against said web tofracture said web, means to cause the fractured web to undulatecomprising a pair of fluted rollers, means to advance said web betweensaid fluted rollersat a speed greater than its speed during thefracturing and succeeding means to advance said web at a speed greaterthan its speed when passing between said iluted rollers to separate thelengths of fibers from one another.

28. The method for producing separated cut lengths of fibers from a webof filaments in a continuous movement which comprises feeding the web offilaments to fracturing means, fracturing said moving web, repeatedlyflexing said web to cause a differential in linear speed between thebers with relation to one another while advancing the web of fibers at aspeed greater than the speed of the filaments through the fracturingmeans, and thereafter advancing said fibers at a speed greater than thespeed of their movement during said ilexlng, whereby the fibers areseparated from one another.

29. Apparatus for producing separate cut lengths from aweb of -flberfilaments which comprises in combination fracturing rollers forfracturing said maments, one of said rollers having helical threadshaving cutting edges. agpsir of uted rollers, each roller having flutes'on its surface which project into the interflute spaces of the otherroller, said flutes being adapted Ito engage the opposite surfaces ofthe fractured web and to cause said web to undulatc, means to maintainsaid fluted rollers apart a sumctent dfstance to prevent the flutes ofone of said rollers from contacting the flutes of the other roller.means to. drive said fluted rollers at m m81surfacespeedgreater-thanthesurfacespeedofl said fracturlng rollers, webmechanism following said nuted rollers for advancing the webof fracturedstaples in the direction of 18 their length to separate them depthwise,said mechanism including an upper means having a movable surfacefrictionally engaging the upper face of the fractured .web and lowermeans 10 27. Apparatus for producing separated cut having a movablesurface frictionally engaging the lower face of the fractured web,devices to drive both of said means at surface speeds greater thanthesurface speed of said uted rollers and to drive one of said means ata surface speed slower than the surface speed of the other, whereby thefractured filaments are separated from one vanother and are formed intoseparate lengths of fibers.

30. The method of converting lfilaments of textile fibers into a sliverof cut lengths, which comprises forming a plurality of filaments into aflat web of cut and drafted bers, advancing the web and rolling saidfibers as they advance into helices to form a sliver having its axisdiagonally disposed to the direction of the advance of said web andadvancing said sliver axially over said web.

ROBERT C. WILmE.

REFERENCES CITED The following references are of record in the file ofthis patent:

UNITED STATES PATENTS Number Name Date Re. 11,524 Cupers Feb. 25, 1896802,492 Birch oct. 24, 1905 1,577,620 Gammeter Mar. 23, 1926 1,693,589Bo.ton Dec. 4. 1928 1,768,221 'Ihoma June 24, 1930 1,786,180 VonTrumbach Dec. 23, 1930 I 1,827,385 Cornibert Oct. 13, 1931 2,031,647Hale Feb. 25. 1936 2,076,951 Kono Apr. 13, 1937 2,137,908 Gies Nov. 22.1938 2,221,716 Morton Nov. 12, 1940 2,234,105 Ashton et al. Mar. 4, 19412,249,083 Kern July 15, 1941 2,260,383 Killers Oct. 28, 1941 2,272,247Paulus Feb. 10, 1942 2,284,635 Campbell June 2, 1942 2,294,771 CampbellSept. 1, 1942 2,323,300 Abbott July 6, 1943 FOREIGN PATENTS NumberCountry Date 457,557 Great Britain Dec. 1. 1936 Germany Oct. 30, 1939

